· BOSAN
How much electricity a compressor upgrade can save cannot be determined from motor rating alone or from a fixed percentage applied to every factory. Operating hours, loaded and unloaded operation, pressure settings and actual tariffs all affect cost. A clear baseline helps establish whether a replacement fits the production schedule and provides a sound basis for checking results.
Record Complete Shifts, Not a Single Reading
Start with daytime shifts, night shifts and non-production periods, recording input power, loaded and unloaded time, and header pressure. Where flow meters are available, compare flow and power on the same timeline. Brief readings can miss equipment starts, concentrated blow-off or shift changes. Monitoring should cover representative production cycles and identify the work being performed.
Separate Avoidable Energy Use
Unloaded operation does not mean zero electricity use. When demand falls, check for prolonged unloaded running and several machines operating at low load simultaneously. Pressure also deserves separate attention: verify the process requirement, distribution losses and station setpoint. Raising pressure to compensate for restrictions or leaks can conceal the real problem; lowering it requires confirmation that the process will remain adequately supplied.
Compare Electricity Costs on a Consistent Basis
Compare alternatives at similar production output, delivery pressure and air-quality requirements, distinguishing compressor consumption from total station consumption. If dryers, cooling systems and other auxiliaries are included, use the same scope on both sides. For time-of-use tariffs, calculate consumption in each charging period. Demand charges and energy charges should be treated separately rather than replaced by one average tariff.
Optimize the System Before Selecting the Equipment Mix
Leak repair, filter pressure-drop checks and control adjustments can proceed alongside equipment selection. Analyze steady base demand separately from variable demand before choosing a single VSD unit, coordinated multiple units or base-load machines with a trim compressor. The final comparison should include electricity, maintenance, standby capacity and service access rather than purchase price alone.
Make Savings Verifiable
Keep records before and after the upgrade and use consistent measurement boundaries. Sharing site pressure, flow, shift patterns and tariffs with BOSAN helps build an equipment and cost comparison that reflects actual operation.